Insulated ornamental siding material



01112.28, 1941. s s, PHlLLlPs 2,260,334

INSULATED ORNAMENTAL SIDING MATERIAL Filed April 1959 SrANLEy S 'PHnLuPs me MLA-JW ATTORN EY Patented Oct. 28, 1941 azeosi insmeren onNAMEN'rAL snnNc MATE:-

Stanley S. Phillips, Norwood, Mass., assigner to Bird & Son, Inc., East Walpole, Mass., a corporation of Massachusetts Application April 8, 1939, Serial No.' 266,796

Claims.

This invention relates to insulated ornamental siding material adapted for use as an outside weather-proof siding for building structures, and

has particularly to do with such material having an ornamental brick simulating appearance, for example, of the general type disclosed in the U. S. patent to Odell, No. 2,021,577 of November 19, 1935. 'I'he present invention, however, repre* sents a substantial improvement over the material of said patent as will hereinafter appear, particularly inl appearance, although also with respect to the bond or union of the insulating board to the asphalt-saturated granular surface layer of felt material.

In accordance with the present invention, a sheet of felt isssaturated with asphalt and then one side thereof is covered throughout by the addition of granular colored mineral material, the color of which conforms to the color of the mortar it is desired to simulate. To such granular surfaced layer there are then applied spaced areas of liquid asphalt arranged to simulate the courses of brick, following which, brick-colored granular particles are deposited thereon and adhered to said areas and only said areas so as to give additional weather protection and simulate bricks laid in a differently colored mortar, by virtue of the exposure of the background or mortar-colored particles in the form of narrow strips representing mortar joints between bricks. Following the preliminary manufacture of the outside exposed portion of felt with the granular material thereon, it is then attached to a relatively thick, stlfl, though soft, fibrous base material by means of a layer of asphalt cement therebetween. Thereafter, and preferably promptly thereafter and before the liquid asphalt cementing medium has had an opportunity fully to stiffen and set up, the assembled insulated siding material is pressed by means of a die provided with at surfaces adapted to bear against the brick-colored granular areas of the felt sheet and with narrow double-ribbed downward projections adapted to ilt between said brick-colored areas, to bear against the intervening mortar-colored areas of the granular surface, the ribs of each pair presenting substantially vertical exterior sides terminating in lower blunt edge surfaces, and with inner converging side surfaces forming a connecting surface therebetween of concave contour. "In this way, when the die is forced downwardly on to the siding, the ribs trim and even off the defining edges of the brick-colored line portions is permitted partially because ofthe relatively soft underlying insulating board which is compressed sufficiently under the pressure of the double-ribbed die portion so as to assist in temporarily forming said lines to provide a convex formation. Each rib exerts a relatively high localized pressure along and adjacent each brickappearing portion so that the granules under each rib are pressed more heavily-but without, however, forcing the granules of the indented lines so deeply that they are obscured by the underlying asphalt.

Asa practical matter, in the manufacture of y the product of this invention, the asphalt in thelines of the indentations'is laterally displaced somewhat towards the center or raised portion Even though the fibrous material along thesev lines may become somewhat broken-down no harm is done for usuallythe fibrous base material, because of its resiliency, tends to assume its original form, but the formation of the convex mortar lines is assisted by the soft fibrous character as just referred to.

The effect of the sloping siding indentations is to change the reflected light coming to the eye from the oblique surfaces thereof, as compared with the light coming from the substantially ver` tical surfaces normal to the plane of the siding, which define the bricks-'with the result that this difference provides a striking likeness to bullpointed brick masonry and with an appreciable desirable shadow effect not present in products heretofore made. l

` The simultaneous application of pressure to the brick-colored areas and to the intervening mortar-colored areas is also an advantage in that it tends to prevent undesirable owing or displacement of the asphalt layer by which the granular surface strip is united to the fibrous base though, perhaps, thinning such layer immediately under the double-ribbed die portions. By applying pressure both tothe mortar lineareas and to the brick appearing areas there is no injurious tendency of the asphalt to be unduly squeezed or bulged so as to impair the surface appearances of the product. f

In the drawing, which illustrates the preferred lform of the invention- Fig. 1 is a perspective view, partly in section, showing" the exposed surface of the insulated ornamental sliding made in accordance with this invention-as applied to a building; 4

lig/ 2 is an enlarged cross-sectional view illustrating the indenting operation as hereinafter more fully described; and

Fig. 3 is an enlarged cross-sectional view of a modified construction in which the fibrous base vmaterial is made up of a number of laminated sheets.

Referring now to ther drawing, the reference numeral III designates asection of brick-simulating-siding made in accordance with the present phalt, the granules of said coating being colored to simulate mortar, and in spaced areas on said coating I3, a second coating I4 of granular cov` ered asphalt, the granule particles of this coating being brick-colored so that the upper surface of each section is provided with areas I5 simulating bricks surrounded by areas I3 simulating mortar. 'Ihe fibrous base II may 'comprise a single relatively thick brous web, as in the instance illustrated in Figs. 1 and 2, or it may be composed of a plurality of laminated fibrous sheets I1, as in Fig. 3, said sheets being suitably secured together as by thin layers I8 of asphalt cement.

'As shown in Figs. 1 and 2, the fibrous base of each siding section I is provided along its `upper edge with a recess |9 in its upper surface,

and along its lower edge with a recess 20 in its under side, said recess 20 forming an extending tongue 2| corresponding in length and thickness to the recess I9 in the upper edge. As will be apparent, the tongue 2I of each section fits into the recess I9 of the next lower sectionin a vertical row to form a smooth lapped joint between the bases of said sections. Preferably, I also provideA for lapping the asphalt-impregnated felt layers I2 of adjacent sections in a vertical row. To this end, I form the upper edge 22 of the layer I2 substantially ush with the lower edge of the recess I9, said edge 22 being preferably slightly above the upper edge of a laterally extending mortar-simulating strip I6, providing therebetween an area or strip 23. The coating I4 of asphalt covered with brick-colored granules which would normally be applied to the coating I3 in said area 23 is omitted and said area 23 is also depressed below the level of the areas I6, as may be done by cutting away slightly the upper surface of the brous base II below said area, or by pressing said area more deeply into the base, as indicated in Fig. 2, or both. The lower edge -of the layer I2 of each section coincides with the lower edges of a row of brick-simulating areas I on said layer and extends beyond the lower edge of the tongue 2| in the fibrous base I|\ a distance approximately equal to the width of the depressed area 23. Thus, when two -siding sec tions are joined together in av vertical row, the lower edge of the layer I2 of the upper section overlies` the upperedge 22 and depressed area 23 of the layer I2 of the lower section to-form a substantially level joint which, since it coincides 4with-an indented side edge of a mortar-simulating strip, is not apparent to the eye.

To forma weatherproof joint between the sides of adjacent siding sections in each horizontal row, the fibrous base I I of each section extends beyond one side edge of the layer |12. as indicated at the right hand side of Fig. 1 while the layer'I2 extends va corresponding tance A.umm in the drawing). Preferamy, the joint coincides with the ends of certain .brick-simulating areas on one of the joined sections, so that the junction line where adjacent said areas has a similar appearance to the indentations formed in the edges of the mortar-simulating areas, thus serving to disguise the junction..

In accordance with the present invention, the

areas I6 simulating mortar are provided at their sides with indentations 24, each indentation having a. substantially vertical outer side 25 (Fig. 3) corresponding with the edge of an adjacent brick-simulating area I5 and an inner side 26,

-preferably sloping inwardly as shown, these indentations serving to define the edges of the brick-simulating areas regularly and sharply from the mortar-simulating areas and to form. the mortar-simulating areas between them into ridges with sloping sides. Preferably, as shown inl Fig. 1, the indentations 24 are continuous around each brick-simulating area but are not extended across the juncture betweenvertical and horizontal mortar-simulating areas.

To form the indentations 24, I may press the siding between dies, preferably shortly after the impregnated felt layer I2 has been cemented to the brous base In Fig. 2, there is illus" trated a section of siding under pressure between dies suitable for the formation of these indentay tions. As there shown, the dies comprise a platen 21 having a recess 28 in one of its surfaces adapted to receive the fibrous base of the siding and a second platen 29 having a genout recesses and said die members secured exerally smooth surface 30 provided at intervals, corresponding to the mortar-simulating areas I6 on the siding, with projecting indentation forming die members 3|. These die members 3| may, as indicated in the drawing, be set in suitably yformed recesses in the surface 30 ofthe platen 29, or said surface may be formed with ternally thereto.

Each die member 3| is, as-shown, preferably l adapted to form a pair of indentations 24 at op- X posite sides of a mortar-simulating area. I6, and

comprises a body portion 32 having smooth substantially vertical external sides 33 and provided in its lower surface with a longitudinal groove 34 having' a substantially at central portion and outwardly sloping sides 35 providing narrow substantially flat surfaces 36 between their lower edges and the lower edge of the adjacent external side 33. At points of juncture between die members 3|, the ridges formed by the grooves in one of the die members are cut away so that the indentations will not be carried across either of the corresponding joining mortar-simulating areas I6 of the siding. The surface 30 of the platen 29 is also provided with a raised. strip 31 along one edge adjacent one of the die members v 3|, said strip corresponding in location and size to the area 23 on the siding and acting to depress the asphalt-impregnated felt in said area below the surface of the areas I6 as previously described.

When the siding is compressed between the platens 21.v and 29, the surface 30 of the platen 29 between the die members 3| contacts the surm sponding areas I5, such as illustratedin Fig. 1.

At the same time, the die members 3| are forced down ontcthe mortar-simulating areas I6, the external sides 33 of the members passing d ownwardly past the corresponding .edges of the areas l and acting to shear off any irregular extensions of said areas, and the lower surface of said members, due to their concave curvature, forming the areas I6 into side indented portions 2 4 and a convexly curved inner portion, as pref viously described.

In the drawing the upper surface of the fibrous base under thev areas I6 is shown as partaking somewhat of the surface curvature produced 4in said areas by the die members 3l, that is, the

layer l2 where it underlies the ribs on the die curved mortar line portions between them. Forv this reason I employ as the base material, a

iibrous material which, while sufiiciently thick and stiff to form, with 4the capping layers, a suitably resistant insulating siding material, is yet sufficiently soft to be somewhat deformed bythe pressure of the die members 3|, in the manner indicated. As a preferred example of such brous base material, I give a fibrous water-laid insulating board,'which may be a solid construction as shown in Figs. 1 and 2, or a laminated construction as shown in Fig. 3, weighing from to 25 pounds per cubic foot, of the order of thickness of to l/2 inch and having an insulating constant of around .45.

While I have illustrated inl the accompanying drawing. preferred embodiments of the improved' insulated ornamental siding of the present invention, and have described herein certain vmethods and materials as preferred for-use in the formation of such siding, it will be understood that I do not intend thereby to limit the scope of the present invention thereto, and that changes may be made in said embodiments, methods, or materials without departing from the spirit andv contrasting color exposed therebetween,4 said resent a plurality of courses of spaced brick with narrow mortar-ioint-simulating areas of contrasting color exposed therebetween, said mortar-joint-simulating areas presenting convex exposed surfaces with the edge portions thereof adjacent the brick-appearing areas deeply indented and with said waterproof sheet depressed 'into said base member, each said indented portion forming a substantially vertical side defining an edge of an adjacent brick-appearing area.

3. An insulated ornamental siding material having, in combination, a, relatively soft though stiff fibrous insulating base member, a waterproof sheet adhesively secured to said base member, brick-colored particles of granular material adhesively secured to said waterproof sheet and covering certain areas only of said sheet to represent a plurality of courses of spaced brick with narrow mortar-joint-simulating areas of contrasting color exposed therebetween, said mortar-joint-simulating areas presenting convex exposed surfaces with the edge portions thereof adjacent the brick-appearing areas deeply indented and with said waterproof sheet depressed into said base member, each said indented portion forming a 'groove wider at the top than at tl.:v bottom and having a substantially vertical side at the outer edge of said mortar-appearing area.

4. An insulated ornamental siding material having, in combination, a relatively soft though stiff fibrous insulating base member weighing from 15 to 25 pounds per cubic foot, an asphalthesively secured to said sheet and completely covering the weather-exposed side of said sheet,

brick-colored particles of granular material adhesively secured over said mortar colored layer and covering certain areas only of saidlayer to represent a plurality of courses of spaced brick with narrow mortar-joint-simulating' areas of mortar-joint-simulating areas presenting convex exposed surfaces with the edges thereof adjacentV the brick-appearing areas deeply indented andv with said felt sheet depressed into said base dentedand with said-waterproof sheet depressed into said base member.

2. An insulated ornamental siding material having, nr combination, a relatively soft though stii! fibrous insulating base member, a waterproof sheet adhesively secured to said base member, brick-colored particles of granular material adhesively secured to said waterproof sheet and covering certainareas only of said sheet vto rep-vl member.

5. An insulated ornamental siding material having, in combinations. relatively soft though stiff brous insulating base member, an asphaltsaturated felt sheet adhesively secured to said base member by a relatively\thin layer of asphalt, a layer of mortar-colored 'granular particles adhesively secured to said sheet land completely covering the weather-exposed side of said sheet, brick-colored particles oi' granular material adhesively secured over said mortar-coloredlayer and covering certain areas onlyof said layer to represent aplurality of courses of spaced brick withy narrow mortar-joint-simulatin'g areas of contrasting color exposed therebetween, said mortar-joint-simulating areas presenting convex exposed surfaces with the edges thereof adjacent the brick-appearing areas deeply indented, the asphalt-saturated felt sheet underlying said depressed portions being pressed into the fibrous' base member. A

, s'riiunnrv s. Pannes.. 

